Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Nonwoven fabric – Nonwoven fabric with a preformed polymeric film or sheet
Patent
1996-11-15
1998-12-29
Zirker, Daniel
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Nonwoven fabric
Nonwoven fabric with a preformed polymeric film or sheet
442398, 428 361, 428 362, 264113, 264120, 264320, 264324, 162146, 162156, 162206, 156245, B32B 2704, B29B 1116, B29C 5112
Patent
active
058541497
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to a paper-made stampable sheet and a light-weight stampable sheet shaped body produced from this sheet and a method of producing the same. Particularly, the light-weight stampable sheet shaped body lined with a decorative skin according to the invention is high in the rigidity and improves an adhesiveness or a non-permeability between a substrate and a skin, if necessary, and is usable in wide fields such as interior member for automobile, household electrical appliances, building materials and the like.
BACKGROUND ART
Recently, the stampable sheet consisting essentially of reinforcing fibers and thermoplastic resin has been noticed as an alternative product for metal worked product because it can be shaped into a complicated form and the resulting shaped body is high in the strength and light in the weight.
Such a stampable sheet is mainly produced by the following two methods. That is, there are:
A plurality of strand reinforcing fibers are entangled with each other by piercing a needle to form a mat of the strand reinforcing fibers and a thermoplastic resin is laminated thereonto, which are heated and pressed and cooled at a compressed state to form a solidified sheet or so-called laminated stampable sheet;
A dispersion of particulate thermoplastic resin and reinforcing fibers dispersed in an aqueous surfactant solution containing fine bubbles is made on a porous support to prepare a sheet-like web (deposit) and then the web is heated to a temperature of not lower than a melting point of the thermoplastic resin but lower than a decomposition point thereof at once, pressed and cooled at a compressed state to form a solidified sheet or so-called paper-made stampable sheet.
The stampable sheet obtained by such a method contains the reinforcing fibers substantially opened to monofilament state, so that when the sheet is again heated to a temperature of not lower than the melting point of the resin but lower than the decomposition point thereof, the resin is molten and hence the fibers restrained by the resin create stress mitigation (spring-back) to form an expansion sheet expanded to not less than several times of original thickness. Then, the expansion sheet is subjected to compression forming, vacuum forming, pressure forming or the like, whereby it is made possible to conduct expansion forming of a light weight stampable sheet shaped body having a given shape. That is, the porous light weight stampable sheet shaped body having a density smaller than that of the stampable sheet and a high face rigidity can be obtained by adjusting a mold clearance at the completion of the expansion forming so as to be larger than the thickness of the stampable sheet before the heating.
When the above laminated stampable sheet is used as a starting material for the expansion forming, the expandability at the heating is poor and hence the sufficient expansion forming can not be conducted. For this end, the paper-made stampable sheet is usually used as a starting material for the above expansion forming.
Moreover, when the light weight stampable sheet shaped body is used in a part requiring the decorativeness, it is general that the expansion sheet is laminated to and integrally united with a skin for decoration during the forming to form a light weight stampable sheet shaped body.
The light weight stampable sheet shaped body and the method of producing the same are proposed in, for example, JPA-60-179234 and JP-A-62-161529. However, it can not be said that the light weight stampable sheet shaped body obtained by the paper-making process according to these proposals is always excellent in rigidity. That is, the expansion material is generally low in rigidity, so that when the light weight stampable sheet shaped body made from a high expanded material having a small basis weight is incorporated into a vehicle body as an interior member for the automobile, it is bent and hence breaks. If the shaped body is not broken, there is a problem that a crease forms in the skin at the bent po
REFERENCES:
patent: 4337116 (1982-06-01), Foster et al.
patent: 4670331 (1987-06-01), Radvan
patent: 4957805 (1990-09-01), Biggs et al.
patent: 5409573 (1995-04-01), Weeks
patent: 5436980 (1995-07-01), Weeks et al.
Fujimaki Masami
Funakoshi Satoru
Kobayashi Yuji
Masui Syohei
Matsumoto Taiji
K-Plasheet Corporation
Kawasaki Steel Corporation Sumitomo Chemical Co., Ltd.
Miller Austin R.
Zirker Daniel
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